Rigid and Flexible HV Battery Cable

ABSTRACT

A conductor arrangement for an electrical energy or data transmission connection includes at least one conductor portion comprising a flexible internal conductor and a thermoplastic hard plastic sheath surrounding the flexible internal conductor. The thermoplastic hard plastic sheath is transformable into a formable state when heated to a threshold temperature defined at a specific softening point, and the thermoplastic hard plastic sheath hardens into a formed state when cooled.

RELATED APPLICATIONS

This application claims priority to German Patent Application Ser. No. 102019201339.2, filed Feb. 1, 2019, the disclosure of which is hereby incorporated by reference in its entirety.

FIELD OF THE DISCLOSURE

The present disclosure relates to a conductor arrangement for an electrical energy or data transmission connection, and in particular to a connection having at least one conductor portion with a flexible internal conductor.

BACKGROUND

Conventional conductor arrangements are known in a wide range of embodiments. Cable clips or additional guide tubes are usually used for the purpose of fixed installation. In addition, the use of rigid solid conductors instead of flexible conductors is also usual for fixedly installed energy transmission connections, wherein said conductors are bent into a respectively desired shape before being installed.

In addition, with a view to simplifying the assembly thereof, an energy supply rail consisting of flexible and rigid portions, such as known from DE 10 2008 035 169 B3, is provided.

There is a need, however, to adapt a conventional conductor arrangement to a fixed installation.

SUMMARY

In the present disclosure, one embodiment of a conductor arrangement for an electrical energy or data transmission connection may include at least one conductor portion having a flexible internal conductor, wherein the flexible internal conductor is surrounded by a thermoplastic hard plastic sheath which can be transformed into a formable state by heating to a threshold temperature T_(g) provided by a specific softening point, and hardens again after cooling.

After corresponding heating of the at least one conductor portion, the conductor arrangement can therefore be installed easily by hand, even in inaccessible or built-in regions as are typically found in an engine compartment of a motor vehicle. After cooling, the at least one conductor portion then retains the shape established during the installation. The conductor arrangement according to the present disclosure not only replaces the use of pre-bent, rigid solid conductors which are correspondingly difficult to handle in unfavorable installation space conditions owing to their lack of flexibility, but also makes it unnecessary to use an excessively high number of cable clips or an additional guide tube. The thermoplastic hard plastic sheath thus represents both an outer sleeve protecting the flexible conductor and a supporting skeleton which maintains the flexible internal conductor in the shape which has been established. The at least one conductor portion can, for example, be heated selectively at a desired bending point by means of a hot-air gun or, alternatively as a whole in an oven.

The thermoplastic hard plastic sheath has a bending strength of more than 50 N/mm² at an operating temperature of 25° C. It can hereby be a hard PVC, PA6 or the like. In such a case, depending on the additives contained, the softening point is approximately 80 to 150° C. In order to ensure that the at least one conductor portion retains its established shape, the bending strength of the hard plastic sheath should in the cooled state take account of the inherent restoring forces of the flexible internal conductor.

The flexible conductor, which extends in the at least one conductor portion, can be designed such that it can be deformed not only lengthwise but also with respect to its cross-section. In this case, the at least one conductor portion can, by corresponding heating and cooling, be changed from an essentially round state to a flattened one in which it can easily pass through, for example, slit-like regions and narrow places.

It is furthermore possible for the flexible internal conductor to be surrounded in at least one further adjoining conductor portion by a flexible protective sheath in the form of a corrugated tube, fabric hose or the like. The at least one further conductor portion serves typically to fit single- or multi-pole plug connectors or any other contacting elements, for example, in the form of high-power connectors such as cable lugs. The plug connectors are contacted electrically to the at least one further conductor portion by a respective crimped connection.

The flexible internal conductor can be a strand consisting of a plurality of individual bare wires. The flexible internal conductor can have a single-core or multi-core design, wherein each core is formed by an associated strand which is in turn surrounded by a flexible insulation. In addition, a metal braiding or a metal foil can be provided for the purpose of shielding from electromagnetic interference.

The flexible insulation or the flexible protective sheath can be made from soft PVC, PE, TEP, PTFE, silicone, silicone-coated fibreglass or the like. In this connection, the term “flexible” refers to a temperature range provided for continuous operation of the relevant conductor arrangement as most plastics harden at sufficiently low temperatures.

Depending on requirements and where the conductor arrangement is to be used, the flexible internal conductor can be produced from copper or aluminium. For weight and cost reasons, the use of aluminium has proven to be effective in the case of energy supply connections with correspondingly large conductor cross-sections, but does entail a high additional cost for the electrical contacting. It is in addition conceivable that the flexible internal conductor is a glass fiber for the purpose of optical data transmission.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned aspects of the present disclosure and the manner of obtaining them will become more apparent and the disclosure itself will be better understood by reference to the following description of the embodiments of the disclosure, taken in conjunction with the accompanying drawings, wherein:

FIG. 1 shows a first embodiment of the conductor arrangement according to the present disclosure of a single-core electrical energy transmission connection,

FIG. 2 shows a section view of the conductor arrangement of FIG. 1,

FIG. 3 shows the conductor arrangement of FIG. 1 after heating and shaping,

FIG. 4 shows a second embodiment of a conductor arrangement according to the present disclosure of a multi-core electrical data transmission connection, and

FIG. 5 shows a cross-sectional view of the conductor arrangement of FIG. 4.

Corresponding reference numerals are used to indicate corresponding parts throughout the several views.

DETAILED DESCRIPTION

The embodiments of the present disclosure described below are not intended to be exhaustive or to limit the disclosure to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the present disclosure.

FIG. 1 shows a first embodiment of a conductor arrangement according to the present disclosure for the case of an electrical energy transmission connection. The conductor arrangement 10 comprises a central first conductor portion 12 and outer second and third conductor portions 14, 16 adjoining the latter. As can be seen in FIG. 2, a continuous flexible internal conductor 18 extends inside the conductor portions 12, 14 and 16. The flexible internal conductor 18 is a copper strand 20 consisting of a plurality of individual bare wires. In the present case, the flexible internal conductor 18 has a single-core design and is surrounded by a flexible insulation layer 22. The flexible insulation layer 22 is made from soft PVC, PE, TEP, PTFE, silicone or silicone-coated fiberglass.

The flexible internal conductor 18 is surrounded in the region of the central first conductor portion 12 by a thermoplastic hard plastic sheath 24. The thermoplastic hard plastic sheath 24, or sheath layer, has a bending strength of more than 50 N/mm² at an operating temperature of 25° C. It may be a hard PVC, PA6 or the like.

The flexible internal conductor 18 is furthermore surrounded in the outer second and third conductor portion 14, 16 by a flexible protective sheath 26, 28 in the form of a corrugated tube 30, 32. The flexible protective sheath 26, 28, or sheath layer, is made from soft PVC, PE, TEP, PTFE, silicone or silicone-coated fibreglass. Alternatively, a fabric hose or the like can also be provided instead of a corrugated tube 30, 32. A plurality of contacting elements 34, 36, 38, which in the present case may be high-power connectors designed as cable lugs 40, 42, 44, are fitted at the outer second and third conductor portion 14, 16. The connectors are electrically contacted with the outer second and third conductor portion 14, 16 by a respective crimped connection 46, 48.

The thermoplastic hard plastic sheath 24 provided in the region of the central first conductor portion 12 can be transformed into a formable state by heating to a threshold temperature T_(g) provided by a specific softening point. The central first conductor portion 12 is heated selectively at a desired bending point by means of a hot-air gun or alternatively as a whole in an oven. The conductor arrangement 10 can then be brought into the desired shape by hand for the purpose of installation, for example, inside an engine compartment of a motor vehicle. After cooling, the thermoplastic hard plastic sheath 24 hardens or stiffens again such that the central first conductor portion 12 retains its shape, shown by way of example in FIG. 3.

The thermoplastic hard plastic sheath 24 here represents both an outer sleeve protecting the flexible conductor 18 and also a supporting skeleton which maintains the flexible internal conductor 18 in the shape which has been established.

The softening point of the thermoplastic hard plastic sheath 24 is, depending on the additives contained, 80 to 150° C.

FIG. 4 shows a second embodiment of a conductor arrangement according to the present disclosure for the case of an electrical data transmission connection.

The conductor arrangement 50 of the data transmission connection in FIG. 4 differs from that of the energy transmission connection of the first embodiment reproduced in FIG. 1 in that the flexible internal conductor 52 according to FIG. 5 has a multi-core structure. Each core 54 is formed by an associated copper strand 56 which in turn is surrounded by a flexible insulation layer 58. In addition, a metal braiding 60 or a metal film 62 indicated in FIG. 5 is provided for the purpose of shielding from electromagnetic interference.

The flexible internal conductor 52 extending in the central first conductor portion 12 is further designed in such a way that it can be deformed not only lengthwise but also with respect to its cross-section shown in FIG. 5. This is achieved by the individual cores 54 being bundled sufficiently loosely inside the surrounding thermoplastic hard plastic sheath 24. In this case, the central first conductor portion can, by corresponding heating and cooling, be changed from an essentially round state to a flattened one in which it can pass through a slit-like region 64 reproduced in FIG. 4 or a comparable narrow place.

Multi-pole plug connectors 66, 68 are fitted to the outer second and third conductor portions 14, 16, in accordance with the multi-core structure of the flexible internal conductor 52. The plug connectors 66, 68 are hereby electrically contacted with the outer second and third conductor portions 14, 16 via respective crimped connections 70, 72.

For the sake of completeness, it should be noted that the use of the conductor arrangement 10 or 50 is not limited to the field of vehicles. Instead, its use can also be envisaged in any other connection such as, for example, in the construction of devices or systems.

While embodiments incorporating the principles of the present disclosure have been disclosed hereinabove, the present disclosure is not limited to the disclosed embodiments. Instead, this application is intended to cover any variations, uses, or adaptations of the disclosure using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this disclosure pertains and which fall within the limits of the appended claims. 

1. A conductor arrangement for an electrical energy or data transmission connection, comprising: at least one conductor portion comprising a flexible internal conductor; a thermoplastic hard plastic sheath surrounding the flexible internal conductor; wherein, the thermoplastic hard plastic sheath is transformable into a formable state when heated to a threshold temperature defined at a specific softening point wherein, the thermoplastic hard plastic sheath hardens into a formed state when cooled.
 2. The conductor arrangement according to claim 1, wherein the thermoplastic hard plastic sheath comprises a bending strength of more than 50 N/mm² at an operating temperature of 25° C.
 3. The conductor arrangement according to claim 1, wherein the flexible internal conductor extends into the at least one conductor portion.
 4. The conductor arrangement of claim 3, wherein the flexible internal conductor is deformable with respect to its cross-section.
 5. The conductor arrangement according to claim 1, further comprising an adjoining conductor portion, wherein the flexible internal conductor is surrounded in by the adjoining conductor portion via a flexible protective sheath.
 6. The conductor arrangement according to claim 1, wherein the flexible internal conductor comprises a single core.
 7. The conductor arrangement according to claim 1, wherein the flexible internal conductor comprises a multi-core design.
 8. The conductor arrangement according to claim 1, wherein the flexible internal conductor comprises copper or aluminium.
 9. The conductor arrangement according to claim 1, wherein the flexible internal conductor comprises a single core design and is surrounded by a flexible insulation.
 10. The conductor arrangement according to claim 9, wherein the flexible insulation comprises PVC, PE, TEP, PTFE, silicone or silicone-coated fiberglass.
 11. A conductor assembly for an electrical energy or data transmission connection, comprising: a conductor portion comprising a flexible multi-core internal conductor; a sheath surrounding the flexible internal conductor; wherein, each core of the multi-core internal conductor comprises a copper strand surrounded by a flexible insulation layer; further wherein, the sheath is deformable into a desired shape when heated to a threshold temperature and cooled thereafter.
 12. The conductor assembly of claim 11, further comprising a metal film surrounding the multi-core internal conductor for shielding electromagnetic interference.
 13. The conductor assembly of claim 11, wherein each core of the multi-core internal conductor is spaced from adjacent cores internally of the sheath.
 14. The conductor assembly of claim 11, wherein the conductor portion is deformable along its length and with respect to its cross-section.
 15. The conductor assembly of claim 11, further comprising: a second conductor portion adjoining a first end of the conductor portion; a third conductor portion adjoining a second end of the conductor portion; a first contact element coupled to the second conductor portion; and a second contact element coupled to the third conductor portion.
 16. The conductor assembly of claim 15, further comprising a flexible sheath layer disposed around the second conductor portion and the third conductor portion.
 17. The conductor assembly of claim 16, wherein the flexible sheath layer comprises a corrugated tube.
 18. The conductor assembly of claim 15, wherein the first contact element and the second contact element comprise cable lugs.
 19. The conductor assembly of claim 15, further comprising a first multi-pole plug connector coupled to the second conductor portion and a second multi-pole plug connector coupled to the third conductor portion.
 20. A conductor arrangement for an electrical energy or data transmission connection, comprising: a first conductor portion comprising an internal conductor having a first end and a second end, the internal conductor comprising a single core; a sheath layer surrounding the internal conductor; a second conductor portion adjoining the first end of the conductor portion; a third conductor portion adjoining the second end of the conductor portion; a first contact element coupled to the second conductor portion; and a second contact element coupled to the third conductor portion; wherein, the internal conductor comprises a single core design and is surrounded by a flexible insulation layer; wherein, the sheath layer is deformable into a formable state when heated to a threshold temperature and then cooled. 